Method and apparatus for improved shoe construction

ABSTRACT

The invention relates to a method and apparatus for providing a sandal or shoe having an outsole with a socklining on top of and in direct contact with the outsole for directly contacting a user&#39;s foot and a cushion having a thickness between approximately ⅛ and 1½ inches, where the cushion is placed between said outsole and said socklining. The sandal or shoe also includes at least one material partially covering a user&#39;s foot extending across the socklining for holding the sandal onto a user&#39;s foot and a securing mechanism extending from the at least one material through the socklining to the outsole for securing the socklining directly to the outsole.

PRIORITY APPLICATION

This application is a Continuation in Part patent application ofcopending U.S. patent application Ser. No. 10/626,139 for a “Method andApparatus for Improved Shoe Construction” filed Jul. 24, 2003, currentlypending.

FIELD OF THE INVENTION

The invention relates to a shoe having improved construction.

BACKGROUND Of THE INVENTION

A variety of different shoe constructions are used by the footwearindustry. For the most part, each shoe construction has characteristicsthat make it particularly well-suited for specific applications. Forexample, some shoe constructions are selected for their durability,others for their flexibility and comfort, while still others areselected for their aesthetic appeal.

In general, shoe construction typically involves a number ofmanufacturing operations or steps. Normally, a significant number ofmanufacturing operations generally results in a more expensive shoe. Ina market where competitive price is often desired, there appears to be aneed to make shoes in an efficient manner. Conventionally, a shoeconstruction may involve an upper being stitched to a forepart of anoutsole by a hand stitch and the rearpart of the outsole may be attachedto the upper by adhesive after a lasting operation. Lasting is typicallywhere a last, an object which simulates a user's foot, is inserted intothe upper and the upper is often then pulled taught around the last andsecured to a tuck, which is removably attached to the bottom of thelast. The tuck generally provides a structure that is adhered to therearpart of the outsole, which in turn results in the upper beingsecured to the outsole in the rearpart of the shoe. Without a tuck, itmay be difficult to secure the upper to the outsole.

A traditional insole is often wrapped with a wrapper around itsperipheral edge to help prevent the edge of the insole from wear. Theinsole with the wrapper is then typically secured to the tuck oroutsole. In a separate operation, a socklining may then be adhereddirectly to the top of the insole for providing a surface adapted toreceive a user's foot because the insole's surface is often coarse.

Another shoe construction, cementing, also often involves a number ofmanufacturing operations. Cementing components of a shoe, such as theupper to the outsole, typically involves a surface preparation stepwhere the surfaces to be cemented, or glued, are clean of debris andreadied, which may also include roughening. Further, there may be anapplication step where the cement is applied to the surfaces. This stepmay also involve measuring and evenly distributing the glue over thesurface.

Further, there may be a pressing step where the surfaces are pressedtogether. Pressing is believed to reduce air that may be trapped betweenthe surfaces and enhances adhesion. Pressing may also include aligningthe surfaces so that the peripheries of the components are flush withone another.

Additionally, once the components are pressed together, cementing oftenrequires a waiting period for the cement to cure, or dry. Generally, notonly does cementing involve some or all of the above mentionedmanufacturing operations, it also involves time, particularly the curingtime.

It is believed that the number of steps and time involved, especially ifuser intervention is required, negatively affects cost and efficiency.The cementing process may be further complicated if the surfaces to beglued are uneven or difficult to reach.

U.S. Pat. Nos. 4,369,589 to Summey (“Summey”) and 3,821,827 to Nadler(“Nadler”) appear to disclose a shoe having cement or glue to secure theupper to the midsole or outsole. Summey seems to disclose the pressingand aligning operations as well as user intervention described above.Summey also seems to disclose an insole as a part of the shoe.

U.S. Pat. No. 4,685,223 to Long (“Long”) seems to relate to a shoehaving an upper, socklining, and outsole sewn together. A cushion seemsto be enclosed by the socklining and the socklining may in turn beenclosed along a peripheral edge by athe upper. A stitch may secure thesocklining and upper to the outsole by penetrating the upper that isfolded about the socklining and the peripheral edge of the socklining.Hence, the socklining does not appear to be sewn directly to theoutsole.

U.S. Pat. No. 6,029,301 by Issler (“Issler”) appears to disclose a shoehaving a channel in the bottom surface of the outsole and an upper incontact with a top surface of the outsole, where a stitch passes fromthe upper to the channel without passing to the bottom surface of theoutsole. The channel seems to protect the stitch from wear due tocontact between the bottom surface and the ground. However, because thechannel appears to be placed within a confined space, dirt, sand, orother debris may get trapped in the space and, as a result, cause wearto the stitch. Moreover, the socklining seems to be adhered to theoutsole or cushion, where adhering or gluing the socklining oftenincreases the number of operations and/or cost for constructing theshoe. Furthermore, should the gluing operation prove to be messy, cleanup operations may be needed to clean the excess glue.

The sockliner of Issler may be modified to be merely placed on top ofthe outsole or cushion without adherence. However, in these situations,the sockliner is often attached to a structure, such as a tuck orinsole, and the entire unit is then placed on top of the outsole orcushion. Without a tuck or insole, the sockliner may not remain on topof the outsole or cushion as it may tend to slide around due to its lackof structural integrity.

Additionally, in all of the above references, the cushioning appears toextend upwardly into an interior volume of the shoe, which is typicallywhere a user's foot is placed. Because the interior volume is oftensized to accommodate the user's foot, increasing the amount ofcushioning to enhance comfort may lead to decreased room for the foot.As a result, the foot may be squeezed, leading to a reduced amount ofcomfort. Therefore, although greater cushioning may be desired, it isoften limited due to the amount of interior volume that would typicallybe sacrificed.

What is desired, therefore, is a shoe that may be constructed in a moreefficient manner, including reduced manufacturing costs and lessmanufacturing operations. What is also desired is a shoe that isefficiently manufactured without sacrificing aesthetic appeal. A furtherdesire is a shoe having enhanced comfort without compromising properfit.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide a shoe withimproved construction.

Another object of the invention is to reduce manufacturing costs withoutsacrificing the shoe quality.

A further object of the invention is to provide a shoe having improvedcushioning without negatively affecting proper fit.

Yet another object is to provide a shoe having a notch that hinderspremature wear on the stitches that secure the shoe together.

These and other objects of the invention are achieved by a sandal havingan outsole with a socklining on top of and in direct contact with theoutsole for directly contacting a user's foot and a cushion having athickness between approximately ⅛ and 1½ inches, where the cushion isplaced between said outsole and said socklining. The sandal alsoincludes at least one material partially covering a user's footextending across the socklining for holding the sandal onto a user'sfoot and a securing mechanism extending from the at least one materialthrough the socklining to the outsole for securing the sockliningdirectly to the outsole.

In some embodiments, the sandal may include a side surface of theoutsole and a notch in the side surface for receiving a stitch andhindering premature wear of the stitch.

In further embodiments, a securing mechanism extends from the sockliningto the notch without extending through a bottom surface of the outsole.In yet even further embodiments, the securing mechanism extends from theat least one material, through the socklining, and to the notch, withoutextending through the bottom surface, for securing the at least onematerial, the socklining, and the outsole together.

In more preferred embodiments, the thickness of the cushion is betweenapproximately ⅛ and 1 inches. In most preferred embodiments, thethickness of the cushion is between approximately ¼ and 9/16 inches.

Optionally, the notch in the side surface of the outsole may anoutermost periphery of the outsole, an inner periphery smaller than theoutermost periphery, and a horizontal surface of extending generallyperpendicular to and connecting the inner and outermost peripheriestogether.

In another embodiment, the above limitations may be applied to a shoerather than a sandal. In still another embodiment, the above limitationsmay be applied to a sandal without the specific thickness requirementsfor the cushion.

In another aspect of the invention, a method for providing a shoeincludes the step of providing an outsole having a side surface andnotching the side surface to provide clearance for a securing mechanismand to hinder the securing mechanism from premature wear. The methodalso includes contacting a socklining to a top surface of the outsole,placing a cushion between the outsole and the socklining, and extendingthe securing mechanism from the socklining to the notch, withoutextending through a bottom surface of the outsole, for securing thesocklining directly to the outsole.

Optionally, the method may include the step of providing an upper indirect contact with the socklining, where the securing mechanism extendsfrom the upper, through the socklining, and to the notch, withoutextending through the bottom surface, for securing the upper,socklining, and outsole together.

In some embodiments, the method further includes notching the bottomsurface upwardly into the outsole and around at least one portion of aperiphery of the outsole.

In other embodiments, the method may also include the steps of providingan outermost periphery and an inner periphery smaller than the outermostperiphery, extending a horizontal surface of the notch generallyperpendicular to and connecting the inner and outermost peripheriestogether, and extending a vertical wall in a generally downwarddirection proximate to the inner periphery and connecting the horizontalsurface of the notch to the bottom surface of the outsole, wherein thehorizontal surface of the notch is between the bottom surface of theoutsole and a top surface of the outsole.

The invention and its particular features and advantages will becomemore apparent from the following detailed description considered withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the shoe in accordance with the invention.

FIG. 2 depicts an assembly view of the components of the shoe shown inFIG. 1.

FIG. 3 depicts a close-up view of the outsole shown in FIG. 1.

FIGS. 4 a–4 d depict various embodiments of the cross section of theoutsole shown in FIGS. 1–3.

FIG. 5 depicts an alternative embodiment of the outsole shown in FIGS.1–3.

FIG. 6 depicts a cross sectional view of the shoe shown in FIG. 1.

FIG. 7 depicts a method for providing the shoe shown in FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts shoe 10 in accordance with the invention. Shoe 10includes outsole 20, socklining 40, footbed 62 placed between socklining40 and outsole 20 for comforting a user's foot, and securing mechanism38 for securing socklining 40 to outsole 20. Shoe 10 also includes upper18 for holding the invention onto a user's foot, where the foot isplaced in interior volume 42 generally defined between upper 18 andsocklining 40.

As shown, shoe 10 is a sandal where upper 18 comprises several straps.In further embodiments, upper 18 is a single strap. In otherembodiments, upper 18 extends over, or covers, most of the foot like asneaker or dress shoe. All that is required is upper 18 comprise atleast one material covering a portion of the foot for holding theinvention onto a user's foot.

As shown more particularly in FIGS. 2 and 3, outsole 20 further includesside surface 25, top surface 24, and notch 30. Outsole 20 also includesoutermost periphery 26 and inner periphery 28, where inner periphery 28is smaller than outermost periphery 26.

In the embodiment of notch 30 shown, notch 30 includes horizontalsurface 32 extending in a generally perpendicular direction fromoutermost periphery 26 to inner periphery 28, where horizontal surface32 connects outermost periphery 26 with inner periphery 28. Notch 30 mayoptionally include a second horizontal surface 36 having the samelimitations as horizontal surface 32. Second horizontal surface 36completes a notch having three sides, as shown in FIG. 3. In thisembodiment, securing mechanism 38 is hindered from wear to a higherdegree than the alternative embodiments described below under FIGS. 4a–4 d, where notch 30 includes 2 sides and is without second horizontalsurface 36.

FIG. 4 a depicts a cross sectional view of outsole 20 shown in FIGS.1–3, where outsole 20 includes lip 21 extending around a periphery ofoutsole 20. Lip 21 and top surface 24 define a cavity for receivingand/or positioning cushion 62. Further, lip 21 provides an anchoringmechanism to which socklining 40 is sewn.

FIG. 4 b depicts an alternative embodiment of outsole 20 where lip 21 iseliminated because lip 21, although advantageous, is not essential forproper operation of shoe 10. Notch 30 includes horizontal surface 32,outermost periphery 26, inner periphery 28, and second horizontalsurface 36.

As depicted in FIGS. 4 c–4 d, notch 30 is shown in alternativeembodiments for hindering securing mechanism 38 from premature wear.Notch 30 is a step-off in FIGS. 4 c–4 d. In FIG. 4 d, notch 30 is avariation of the step-off of that shown in FIG. 4 c.

In FIG. 4 c, notch 30 includes horizontal surface 32, outermostperiphery 26, and inner periphery 28 having the same limitations asdescribed above under FIG. 3. As shown in FIG. 4 c, notch 30 does notinclude second horizontal surface 36 but has vertical wall 34 extendingin a generally upward direction in a proximate location to innerperiphery 28 for connecting horizontal surface 32 of notch 30 and topsurface 24 of outsole 20. As shown, horizontal surface 32 of notch 30 isbetween bottom surface 22 and top surface 24 of outsole 20.

As shown in FIG. 4 c, notch 30 is a step-off in top surface 24. However,in further embodiments, notch 30 is any recess, indentation, relief,channel, groove, or etching in side surface 25 of outsole 20 sufficientto provide clearance for securing mechanism 38 such that wear uponsecuring mechanism 38 is inhibited or reduced. Notch 30 may be formed ormanufactured using any known or novel methods or equipment, such asmachining, molding, grinding, etching, laser cutting, or the like.

As shown in FIG. 4 d, notch 30 is also a step-off and is a variation ofthe step-off shown in FIG. 4 c. Notch 30 of FIG. 4 d includes horizontalsurface 32, outermost periphery 26, and inner periphery 28 having thesame limitations as described above under FIGS. 3 and 4 c. As shown inFIG. 4 d, notch 30 does not include second horizontal surface 36 but hasvertical wall 34 extending in a generally downward direction in aproximate location to inner periphery 28 for connecting horizontalsurface 32 of notch 30 and top surface 24 of outsole 20.

As shown in FIGS. 4 c and 4 d, notch 30 extends inwardly toward a centerof outsole 20 without surrounding securing mechanism 38 on at least onehorizontal side. In this manner, debris or dirt may have difficultycollecting in notch 30 because notch 30 lacks a horizontal wall, wheremore than one horizontal or side wall may permit debris to collectbetween the horizontal walls.

Although notch 30 is shown in FIGS. 1–3, 4 c, and 4 d to continuouslyextend around an entire periphery of outsole 20, it is not necessary forthe invention to function properly. In an alternative embodiment, shownin FIG. 5, notch 30 and lip 21 extend around a portion of the peripheryof outsole 20. All that is required of notch 30 is that it provideclearance for securing mechanism 38 so that wear on securing mechanism38 is inhibited.

As shown in FIGS. 2 and 6, socklining 40 is in direct contact with topsurface 24 of outsole 20. Moreover, socklining 40 is secured to topsurface 24 by securing mechanism 38 extending from socklining to notch30, without extending to bottom surface 22 of outsole 20. In thismanner, socklining 40 need not be glued or adhered to top surface 24 ofoutsole 20, resulting in shoe 10 being made more efficiently. Byextending securing mechanism 38 through upper 18, socklining 40, and tonotch 30, shoe 10 is completed without a need for an insole, footbed orcushion, or tuck. This results in shoe 10 being manufactured moreefficiently with less operations.

One advantage shoe 10 provides over traditional shoe constructions isthat socklining 40 is secured as upper 18 is secured to outsole 20,obviating later operations for securing socklining 40. In someembodiments, securing mechanism 38 may pass through upper 18, socklining40, and notch 30 in a single sewing operation to further enhanceefficiency.

As shown in FIGS. 2 and 6, cushion 62 differs from traditional cushionsin that cushion 62 is generally thicker, and preferably several timesthicker, than those conventionally used. The thickness of cushion 62 isbetween approximately ⅛ and 1½ inches. More preferably, cushion 62 has athickness of between approximately ⅛ and 1 inches. Most preferably,thickness of cushion 62 is between approximately ¼ and 9/16 inches.Hence, cushion 62 provides enhanced comfort to the user's foot. Also,because shoe 10 is made approximately 3–5 times larger than traditionalsandals or shoes, including an unusually enlarged upper 18 and interiorvolume 42, cushion 62 does not encroach into interior volume 42 touncomfortably squeeze the user's foot, which would typically be theresult of using cushion 62 in traditional shoes. Therefore, cushion 62of shoe 10 is not merely a design change from traditional cushionsbecause such size and/or thickness of cushion would negatively affectthe comfort of traditional shoes.

In another aspect of the invention, a method 100 for providing shoe 10is shown in FIG. 7.

Method 100 includes the step of providing 102 an outsole having a sidesurface, a bottom surface for contacting the ground, and a top surface.Method 100 also includes notching 104 the side surface to provideclearance for a securing mechanism, where the notched bottom surfacewill hinder the securing mechanism from premature wear due to the bottomsurface contacting the ground.

Method 100 further includes the steps of providing 106 a socklining andcontacting 108 the socklining to the top surface of the outsole.Optionally, method 100 may include placing 110 a cushion between thesocklining and the top surface of the outsole.

To secure the socklining to the outsole, method 100 extends 112 thesecuring mechanism from the socklining to the notch, without extendingthe securing mechanism through the bottom surface, for securing thesocklining directly to the outsole. The securing mechanism does notextend through the optional cushion, but the cushion is held in place bybeing sandwiched between the socklining, outsole, and securing mechanismthat extends from the socklining to the notch.

In some embodiments, method 100 optionally provides an upper in directcontact with the socklining and extending the securing mechanism fromthe upper, through the socklining, and to the notch, without extendingthrough the bottom surface, for securing the upper, socklining, andoutsole together.

In further embodiments, method 100 includes the step of providing anoutermost periphery and an inner periphery smaller than the outermostperiphery, extending a horizontal surface of the notch generallyperpendicular to and connecting the inner and outermost peripheriestogether. In still further embodiments, method 100 may optionallyinclude extending a vertical wall in a generally downward directionproximate to the inner periphery and connecting the horizontal surfaceof the notch to the top or bottom surface of the outsole, wherein thehorizontal surface of the notch is between the bottom surface of theoutsole and a top surface of the outsole.

In alternative embodiments, instead of notching 104 the side surfacearound an entire periphery of the outsole, method 100 notches the sidesurface around at least one portion of a periphery. Hence, the securingmechanism likewise does not extend around the entire periphery of theshoe but only in the areas of the notches.

Although the invention has been described with reference to a particulararrangements of parts, features and the like, these are not intended toexhaust all possible arrangements or features, and indeed many othermodifications and variations will be ascertainable to those of skill inthe art.

1. A sandal that is open over a user's toe, comprising: an outsolehaving a flat top surface that extends from a front part to a rear partand from a left side to a right side; a socklining on top of and indirect contact with said flat top surface for directly contacting auser's foot; a cushion having a thickness between approximately ⅛ and 1½inches; said cushion is placed between said flat top surface and saidsocklining; a material partially covering a user's foot extending acrosssaid socklining for holding the sandal onto a user's foot withoutextending over the toes; and a securing mechanism extending from saidmaterial through said socklining to said outsole for securing saidsocklining directly to said flat top surface.
 2. The sandal according toclaim 1, wherein said outsole includes a side surface and a notch insaid side surface for receiving said securing mechanism and hinderingpremature wear of said securing mechanism.
 3. The sandal according toclaim 2, where said securing mechanism extends from said socklining tosaid notch without extending through a bottom surface of said outsole.4. The sandal according to claim 2, said securing mechanism extends fromsaid at least one material, through said socklining, and to said notch,without extending through said bottom surface, for securing said atleast one material, said socklining, and said outsole together.
 5. Thesandal according to claim 2, wherein said notch is a relief extendinginwardly toward said outsole and around at least a portion of aperiphery of said outsole.
 6. The sandal according to claim 2, whereinsaid notch includes an outermost periphery of said outsole, an innerperiphery smaller than said outermost periphery, and a horizontalsurface of said notch extending generally perpendicular to andconnecting said inner and outermost peripheries together.
 7. The sandalaccording to claim 1, wherein said thickness is between approximately ⅛and 1 inches.
 8. The sandal according to claim 1, wherein said thicknessis between approximately ¼ and 9/16 inches.
 9. A shoe that is open overa user's toes, comprising: an outsole; a socklining on top of and indirect contact with said outsole for directly contacting a user's foot;a cushion having a thickness between approximately ⅛ and 1½ inches; saidcushion is placed between said outsole and said socklining; a materialpartially covering a user's foot extending across said socklining forholding the sandal onto a user's foot without extending over the toes; asecuring mechanism extending from said socklining to said outsole forsecuring said socklining directly to said outsole; and said outsoleincludes a side surface and a notch in said side surface for receivingsaid securing mechanism and hindering premature wear of said securingmechanism; said securing mechanism extending around an entire peripheryof said outsole and said socklining.
 10. The shoe according to claim 9,further comprising an upper in direct contact with said socklining. 11.The shoe according to claim 9, wherein said outsole includes a notch,said notch includes an outermost periphery of said outsole, an innerperiphery smaller than said outermost periphery, and a horizontalsurface of said notch extending generally perpendicular to andconnecting said inner and outermost peripheries together.
 12. The shoeaccording to claim 11, said securing mechanism extends from said atleast one material, through said socklining, and to said notch, withoutextending through said bottom surface, for securing said at least onematerial, said socklining, and said outsole together.
 13. A method forproviding a sandal that is open over a user's toes, comprising the stepsof: providing an outsole having a side surface; notching the sidesurface to provide clearance for a securing mechanism and to hinder thesecuring mechanism from premature wear; contacting a socklining directlyto a top surface of the outsole; placing a cushion having a thicknessbetween approximately ⅛ and 1½ inches between the outsole and thesocklining; extending a material across the socklining for holding thesandal onto a user's foot without extending over the toes; and extendingthe securing mechanism from the socklining to the notch, withoutextending through a bottom surface, for securing the socklining directlyto the outsole.
 14. The method according to claim 13, further comprisingthe step of providing an upper in direct contact with the socklining,where the securing mechanism extends from the upper, through thesocklining, and to the notch, without extending through the bottomsurface, for securing the upper, socklining, and outsole together. 15.The method according to claim 13, further comprising the step ofnotching the bottom surface upwardly into the outsole and around atleast one portion of a periphery of the outsole.
 16. The methodaccording to claim 13, further comprising the step of providing anoutermost periphery and an inner periphery smaller than the outermostperiphery, extending a horizontal surface of the notch generallyperpendicular to and connecting the inner and outermost peripheriestogether, and extending a vertical wall in a generally downwarddirection proximate to the inner periphery and connecting the horizontalsurface of the notch to the bottom surface of the outsole, wherein thehorizontal surface of the notch is between the bottom surface of theoutsole and a top surface of the outsole.